DUROMAX XP85000E, User Manual

Page 1: ...made every effort to ensure the accuracy of the information in this manual We reserve the right to change this product at any time without prior notice 5800 Ontario Mills Pkwy Ontario CA 91764 USA www duromaxpower com Call our Customer Care Team Toll Free 8 5pm PST Mon Fri 844 DUROMAX User Manual REV XP8500E 07072020 ...

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Page 3: ...g the Generator Using Recoil Start 34 Starting the Generator 3 Shipping Braces 21 Wheel Kit Installation 22 Connect the Battery 24 Adding Oil 25 Adding Gasoline 26 Grounding the Generator 27 High Altitude Operation 27 Generator Setup 5 AC Usage 38 Connecting a Load to the Generator 40 DC Usage 42 Using the Generator 2 Quick Start Guide 14 Generator Components 16 Package Contents 18 Quick Start ...

Page 4: ...50 Spark Plug Maintenance 52 Emptying the Gas Tank 54 Cleaning the Fuel Filter Cup 56 Storage and Transportation 57 Specifications 58 68 Basic Troubleshooting 60 Changing Inspecting the Carbon Brushes 61 Changing Inspecting the AVR 63 Wiring Diagram 66 Maintenance and Care Warranty Troubleshooting 9 72 Contact Information ...

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Page 6: ...daily lives Inevitability when disaster strikes and we are left without power for a prolonged period of time our way of life is put at risk This is by far the most critical time for reliable portable power DUROMAX FOR WORK On the job site portable power allows you the ability to get work done in remote locations when traditional power sources are usually unavailable Equipment like table saws sande...

Page 7: ... simple we are committed to Powering Everyone Anywhere STOP Please do not return to the store DuroMax representatives are ready to help you with any questions concerns or issues about your new product We can guide you through assembly start up and how to operate your new generator We want you to be able to put your new generator to use right away CALL US BEFORE YOU CONSIDER RETURNING THE PRODUCT 1...

Page 8: ...st can exceed 150 F 65 C Do not touch hot surfaces Pay attention to warning labels on the generator denoting hot parts of the machine Allow generator to cool several minutes after use before touching engine or areas which heat during use The safety alert symbol is used with one of the safety words DANGER CAUTION or WARNING to alert you of hazards Please pay attention to these hazard notices both i...

Page 9: ...lve to the off position and disconnect the spark plug WARNING This generator produces a powerful voltage which can result in electrocution ALWAYS ground the generator before using it see the Grounding the Generator portion of the PREPARlNG THE GENERATOR FOR USE section The generator should only be plugged into electrical devices either directly or with an extension cord NEVER connect to a building...

Page 10: ...bove safety notices please familiarize yourself with the safety and hazard markings on the generator GENERAL SAFETY PROCEDURES DANGER DO NOT OVERFILL THE GAS TANK OVERFILLING CAN RESULT IN A FIRE EXPLOSION OR DEATH 1 5 10 ...

Page 11: ...DON T TOUCH CAUTION HIGH TEMPERATURE DANGER HOT EXHAUST KEEP SAFE DISTANCE DON T TOUCH BURN RISK CARBON MONOXIDE SAFE DISTANCE 11 ...

Page 12: ...ice in the future If you have a paper receipt staple it here for easy reference If you purchased the unit online save the email receipt where you can access it and record your details here for convenience in the future Purchase Date ____________________________________________ Order Number ____________________________________________ Retailer Name _____________________________________________ Seri...

Page 13: ...utely mandatory to keep your family safe from carbon monoxide But there s even more you can do By educating yourself about all carbon monoxide risks you ll be better prepared to protect your family from this colorless odorless threat Visit takeyourgeneratoroutside com for more information ...

Page 14: ... when you see fuel in the bottom of the fuel filter cup DO NOT overfill the tank 3 Turn gas valve on The gas valve is located above the recoil start on the bottom of the fuel tank Rotate the valve clockwise to the vertical position to turn on the gas supply 5 Add oil The oil fill cap is located on the lower engine block to the right of the recoil start housing Remove the oil fill cap and fill with...

Page 15: ...and increase air into the carburetor for normal running 8 Connect devices Connect your devices to the receptacles on the front panel Start with the largest loads first 10 Start generator The key switch is located on the left side of the front power panel Insert the key and turn to the start position to start the generator Allow the key to return to the run position once started 7 Turn breaker on T...

Page 16: ...l in the gasoline tank 4 Fuel Cap Allows access to fill the gasoline tank 5 Circuit Breaker Resettable switch that protects the generator from electrical overload 6 120 240v 4 Prong Twist Lock Use to connect electrical devices that run 120 or 240 Volt 60Hz single phase AC current NEMA L14 30 7 Ground Terminal Connect a ground wire here to properly ground the generator 8 120v 3 Prong Receptacle Use...

Page 17: ... Start to start the engine without the electric start 15 Fuel Filter Cup Traps dirt and debris in gasoline before it enters the engine 16 Fuel Valve O n Off Valve that allows fuel into the engine 17 Spark plug Provides ignition to the engine 18 Muffler Reduces engine emissions and reduces noise 19 Power Boost DuroMax exclusive Power Boost doubles the amperage available in 120v Only for heavy loads...

Page 18: ...llowing items are included with your generator Double Sided Screw Driver Oil Funnel w hose Spanner Spark Plug Wrench Plug Ends Phillips and slot blade screwdriver used for generator maintenance Used to add oil to the generator without messy spills Assorted wrenches used in generator maintenance and assembly Commonly 8mm 10mm 13mm and 15mm Used in spark plug maintenance inspection and installation ...

Page 19: ...GENERATOR SETUP Proper setup of your generator will get you going as soon as possible while making sure you and your equipment are safe and cared for ...

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Page 21: ...ER Attempt this if you have put fuel or oil in the generator 1 Step 1 Remove Shipping Braces Remove braces The shipping braces prevent engine movement during shipment Flip the generator over and remove the brightly colored braces between the motor and the frame and the wood brace under the generator 2 21 Note Shipping braces can be thrown away They will not be needed again ...

Page 22: ...ashers a Place one of the large washers onto both sides of the axle behind the wheel 4 Install wheel axle a Insert wheel axle bolts through the frame and secure with the provided nut and wrenches 2 GENERATOR SETUP CONTINUED Install wheel axle bracket a Insert wheel axle bracket bolts through the frame and secure with the provided nut and wrenches 3 22 ...

Page 23: ...o secure the wheels 7 Install outside wheel washers a Place the other large washers onto each side the axle in front of the wheel 6 Install handles a Attach the handles to the brackets on the frame using the provided bolts and nuts b Flip the assembled generator over onto its wheels and support brackets Do not over tighten the handles it will prevent free movement 8 ...

Page 24: ...ther end needs to be connected to the battery b Route the free end to the negative battery terminal 2 Connect the negative cable a Push the black rubber boot up the wire to expose the connector b Securely connect the free end of the battery cable to the negative battery terminal using the screw and nut from the battery with the screwdriver and wrench from the toolkit 3 The generator battery is dis...

Page 25: ...s service life a Make sure the generator is on a level surface b Unscrew the oil filler dipstick cap from the engine c Using a funnel add the appropriate amount of oil into the crankcase You will know the crankcase is full when the oil level has reached the lower lip of the opening you have just poured the oil into d Replace the oil filler cap Step 4 Adding Oil Engine oil recommended SAE 10W 30 Vi...

Page 26: ...uns smoothly use only FRESH UNLEADED GAS WITH AN OCTANE RATING OF 87 OR HIGHER Never use an oil gasoline mixture Never use old gas Avoid getting dirt or water in the fuel tank Gas can age in the tank and make it hard to start up the generator in the future Never store generator for extended periods of time with fuel in the tank Model Number XP8500E Gas Tank Capacity 7 9 US Gal 30L DANGER DO NOT OV...

Page 27: ...at differs from that at which this engine was certified for extended periods of time may increase emissions High altitude performance can be improved by specific modifications to the carburetor If you always operate your generator at altitudes above 3 000 feet 900 meters have a dealer perform this carburetor modification This engine when operated at high altitude with the carburetor modifications ...

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Page 29: ...e are still steps you should take to prepare it for operation each time you use it IMPORTANT At this point you should be familiar with the procedures described in the first portion of this section entitled GENERATOR SETUP If you have not yet read this section go back and read it now ...

Page 30: ...the oil filler dipstick cap c With a dry cloth wipe the oil off of the stick on the inside of the cap d Insert the dipstick as if you were replacing the cap and then remove it again There should now be oil on the stick If there is no oil on the stick or oil only at the very end of the stick you should add oil until the engine crankcase is filled see Adding Oil portion of the Maintenance section e ...

Page 31: ...the gas level Optional DANGER DO NOT OVERFILL THE GAS TANK OVERFILLING CAN RESULT IN A FIRE EXPLOSION OR DEATH 1 5 WARNING Gasoline and gasoline fumes are highly flammable Do not fill the tank near an open flame Always allow the engine to cool for several minutes before refueling DO NOT overfill the fuel tank Fuel expands when shaken or heated ALWAY leave 11 2 space or more at the top of the tank ...

Page 32: ... recoil start on the bottom of the fuel tank Rotate the valve clockwise to the vertical position to turn on the gas supply The choke lever is located above the air cleaner to the right of the recoil start Slide the lever to the left to cut the air supply and allow more gas into the engine to start The key switch is located on the left side of the front power panel Insert the key and turn to the st...

Page 33: ...or more than 5 seconds can damage the motor If the engine fails to start release the switch and wait 10 seconds before operating the starter again 33 Turn engine switch to ON When the engine starts allow the engine switch to return to the ON position 5 Open choke Push the choke to the OPEN position as the engine warms up 6 ...

Page 34: ...ine see step 2 on pg 36 If using propane see steps 2 4 on pg 38 2 Close choke The choke lever is located above the air filter to the left of the recoil start Slide the lever to the left to cut the air supply and allow more gas into the engine to start 3 Turn engine switch to Run The key switch is located on the left side of the front power panel Insert the key and turn to the run position to start...

Page 35: ...eft side panel next to the air filter Pull the recoil handle slowly until resistance is felt then quickly pull the recoil handle until fully extended 5 Open choke After the engine has started Push the choke to the OPEN position as the engine warms up 6 Turn breaker on connect The breaker is located on the right side of the front power panel Flip the breaker up to allow the power to flow to the rec...

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Page 37: ... still steps you should take to prepare it for operation each time you use it IMPORTANT At this point you should be familiar with the procedures described in the first portion of this section entitled GENERATOR SETUP if you have not yet read this section go back and read it now 37 ...

Page 38: ...ed the rated wattage of the generator itself To calculate the total wattage requirement of the electrical devices you wish to connect find the rated or running wattage of each device This number should be listed somewhere on the device or in its instruction manual If you cannot find this wattage you may calculate it by multiplying the Voltage requirement by the Amperage drawn Watts Volts x Amps If...

Page 39: ...ectric drill 600 900 Television 500 0 Deep freezer 500 800 Garage door opener 480 600 Stereo 400 0 Box fan 300 600 Clock radio 300 0 Security system 180 0 DVD Player 100 0 Common light bulb 75 0 CAUTION The generator can only run at its surge wattage capacity for a very short time Connect only electrical devices requiring a rated running wattage equal to or less than the rated wattage of the gener...

Page 40: ...nnected the 240v receptacle Plug in devices Turn breaker on Turn on connected devices Plug in devices to the appropriate receptacle When using the generator in 120 240v mode balance the load as closely as possible Placing more load on one side of the circuit will reduce the breaker trip period Flip the circuit breaker up to the on position to allow power to the receptacles Start or turn on applian...

Page 41: ...ust be in the 120 240V position If only 120V appliances are being connected to the generator select the 120V ONLY position to double the 120v amperage and automatically balance the load Long or thin cords can drain the power provided to an electrical device by the generator When using such cords allow for a slightly higher rated wattage requirement for the electrical device See table below for rec...

Page 42: ...sitive receptacle Start Generator Connect one charging wire to the positive terminal on the battery and the other charging wire to the negative terminal on the battery Connect the free end of the positive wire to the positive receptacle outlet on the generator The key switch is located on the left side of the front power panel Insert the key and turn to the start position to start the generator Al...

Page 43: ...n charging a battery DANGER If battery acid gets on your skin flush with water If battery acid gets in your eyes flush with water and call a physician immediately DANGER If battery acid is swallowed drink large quantities of milk and call a Physician immediately 43 Connect negative receptacle Carefully connect the free end of the negative wire to the negative receptacle on the generator 4 Disconne...

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Page 45: ...nce and storage of your generator is essential to ensure trouble free use of your generator when you need it By following the maintenance and care requirements you can keep your generator running smooth and efficient for years to come 45 ...

Page 46: ...LACE SPARK ARRESTOR CLEAN IDLE SPEED CHECK ADJUST VALVE CLEARANCE CHECK ADJUST COMBUSTION CHAMBER CLEAN 500 HOURS FUEL TANK FILTER CLEAN FUEL TUBE CHECK EVERY 24 MO REPLACE IF NECESSARY TO BE PERFORMED AT MONTHS INDICATED OR HOUR INTERVAL WHICHEVER COMES FIRST 46 WARNING Improper maintenance or failure to correct a problem before operation can cause a malfunction in which you can be seriously inju...

Page 47: ...MAINTENANCE LOG Date Generator Hours Maintenance Performed 47 ...

Page 48: ...rew the oil filler dipstick cap c With a dry cloth wipe the oil off of the stick on the inside of the cap d Insert the dipstick as if you were replacing the cap and then remove it again There should now be oil on the stick If there is no oil on the stick or oil only at the very end of the stick you should add oil until the engine crankcase is filled see Adding Oil portion of the Maintenance sectio...

Page 49: ...to an approved oil disposal container Contact your local auto parts store for information on oil disposal 2 Replace drain plug Replace the oil drain plug and tighten with a 12 mm hex wrench 3 49 Worn out or dirty oil does not cool the generator properly and can lead to catastrophic engine damage In addition to regular oil changes it is necessary to drain the oil from the crankcase if it has become...

Page 50: ...r to enter the engine or dirty air to enter the engine causing overheating and engine wear MAINTENANCE AND CARE CONTINUED Cleaning the air filter 50 Remove the filter cover Remove filter Clean out filter casing Release the clips on the top and bottom of the cover and remove the filter cover Remove the sponge like elements from the casing Wipe the dirt from inside the empty air cleaner casing 1 2 3...

Page 51: ...lace the cover 7 Washcleanerelement Wash the sponge like elements in household dish detergent and warm water 4 Drycleanerelement Pat dry on a dry cloth and allow the elements to dry completely 5 6 Addengineoiltoelements Soak the dry elements in a small amount of engine oil Ring out any excess oil ...

Page 52: ...lug Maintenance Remove spark plug cap Removesparkplug Inspectsparkplug Pull on the spark plug cap to remove it Unscrew the spark plug from the generator using the spark plug wrench included with this product Visually inspect the spark plug If it is cracked or chipped discard and replace it with a new spark plug We recommend using an F6RTC spark plug such as NGK BPR6ES 1 2 3 SPARK PLUG CONSULTMANUA...

Page 53: ...nd re gap If you are re using the spark plug use a wire brush to clean any dirt from around the spark plug base and then re gap the spark plug 5 Install spark plug Replace spark plug cap Screw the spark plug back into its place on the generator using the spark plug wrench Replace the spark plug cap 6 7 53 ...

Page 54: ...e fuel filter cup of any fuel 1 2 3 CAUTION Do not store fuel from one season to another Gasoline sold at the pump today contains additives such as ethanol that even when stored properly may damage the fuel system components If you have been using gasoline in your generator before storing your generator for extended periods of time you should drain your generator fuel tank of gasoline MAINTENANCE ...

Page 55: ...lve to the ON position Drain all the gas from the generator 4 Shut fuel valve off Replace fuel filter cup Store emptied gas Turn the fuel valve to the OFF position Reinstall the fuel filter cup Store the emptied gasoline in a suitable place and add fuel stabilizer to keep fuel fresh and usable 5 6 7 55 ...

Page 56: ...valve to the OFF position 1 Cleaning the fuel filter cup Remove fuel filter cup Clean filter cup Replace fuel filter cup Unscrew the fuel filter cup from the fuel valve using a wrench Clean the cup of all sediment using a rag or brush Reinstall the fuel filter cup 2 3 4 ...

Page 57: ...the unit to stall out 5 Turn off the key 6 Drain the fuel tank See Emptying the Gas Tank in the Maintenance section 7 Drain the carburetor a Remove the drain bolt from the carburetor b Drain the small amount of remaining fuel from the carburetor bowl 8 Oil the cylinder a Remove the spark plug b Put 2 tbsp of 10w30 motor oil directly into the spark plug hole c Pull the recoil start one time d Repla...

Page 58: ... AC Phase Single DC Voltage 12V DC Amperage 8 3A Dimensions LENGTH 28in WIDTH 22in HEIGHT 23in Engine Type 4 Stroke OHV Forced Air Ignition System Non Contact Transistor Displacement 420cc Starting Type Electric Fuel Tank Capacity 7 9 US Gal 30L Oil Capacity 37 fl oz 1 1L Run Time 50 10 hr Noise Level 74db 58 ...

Page 59: ...TROUBLESHOOTING This section of the manual is to help you troubleshoot problems with your generator 59 ...

Page 60: ... to a level surface Oil is low Add change oil Engine runs but there is no electrical output Circuit breaker is Off Turn on circuit breaker Wiring connection is bad Replace extension cord s Device connected to generator is malfunctioning Disconnect malfunctioning device Generator runs but does not support all electrical devices connected Generator is overloaded Disconnect 1 or more items to reduce ...

Page 61: ...bon brushes are wearable parts and should be inspected every 250 running hours Remove generator cover Remove bolt from brush Disconnect AVR wires Remove the 2 bolts of the generator cover then pull the cover off the generator Remove the bolt holding the carbon brush Remove the two wires from the AVR on the carbon brush 1 2 3 61 ...

Page 62: ...h Install new carbon brush with bolt 4 Connect AVR wires Insert and connect the 2 wires from the AVR be sure to connect and correctly 5 6 Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts TROUBLESHOOTING CONTINUED 62 ...

Page 63: ...or If the generator is overheated or overloaded the AVR may be damaged and require replacement Remove generator cover Remove AVR bolts Disconnect AVR wire clip Remove the 2 bolts of the generator cover then pull the cover off the generator Remove the 2 bolts holding the AVR Disconnect the wire clip 1 2 3 63 ...

Page 64: ...h Remove the 2 wires from the AVR on the carbon brush 4 Install new AVR Install the new AVR with the 2 bolts 5 6 Reconnect wires to brush Insert and connect the 2 wires from the AVR be sure to connect and correctly Changing Inspecting the AVR Continued TROUBLESHOOTING CONTINUED 64 ...

Page 65: ...Replace generator cover Replace the back cover of the generator and secure it with the 2 bolts 8 65 ...

Page 66: ...WIRING DIAGRAM 66 ...

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Page 68: ...EXPRESSED OR IMPLIED U S EPA AND CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board The United States Environmental Protection Agency US EPA and DuroMax Power Equipment are pleased to explain the emission control system warranty on your 2020 2021 year small off road engine In the United States and California new small off road eng...

Page 69: ...844 387 6629 WEBSITE www duromaxpower com ADDRESS 5800 Ontario Mills Pkwy Ontario CA 91764 This telephone number is only for the engines which the company name DuroMax Power Equipment on the emission label DEFECTS WARRANTY REQUIREMENTS a The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser b General Emissions Warranty Coverage DuroMax Power Equipment...

Page 70: ...sions of Subsection 4 above warranty services or repairs must be provided at all DuroMax Power Equipment distribution centers that are franchised to service the subject engines 6 The owner must not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective provided that such diagnostic work is performed at a warranty station 7 DuroMax Power Equipment...

Page 71: ...or spacer if applicable ii EGR rate feedback and control system 5 Air Injection System i An air pump or pulse valve ii Valves affecting the distribution of flow iii Distribution manifold 6 Catalyst or Thermal Reactor System i Catalytic converter ii Thermal reactor iii Exhaust manifold 7 Particulate Controls i Traps filters precipitators and any other device used to capture particulate emissions 8 ...

Page 72: ...ors are your lifeline in the event of an emergency Should you have any problems please contact our customer service department DUROMAX POWER EQUIPMENT 5800 Ontario Mills Parkway Ontario CA 91764 Customer Service 844 DUROMAX Customer Service Hours 8 5 pm PST Website www duromaxpower com Email customerservice duromaxpower com ...

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Page 74: ...5800 Ontario Mills Parkway Ontario CA 91764 United States 844 DUROMAX REV XP8500E 07072020 ...